System and method for controlling gas consumption by gas-fired water heaters

ABSTRACT

A system and a method is described for remotely controlling gas consumption by a power vented gas-fired water heater to reduce consumption of gas by a consumer connected to a gas distribution bank network of a gas provider during overload periods where gas demand is at a peak. The system comprises a consumer controller in communication with the gas provider whereby the controller can operate a modulating gas control valve either directly or through the control of the fan speed of a power vented blower to reduce the supply of gas to the burner of the gas-fired water heater when asked by the provider to do so. Temperature sensors are associated with the water holding tank of the gas-fired water heater to feed water temperature signals to a computer of the controller whereby to enable the controller to execute informed corrective action for the reduction in gas consumption by regulating the gas control valve to reduce the supply of gas to the burner of the water heater.

This is a divisional application of U.S. patent application Ser. No. 16/350,038 filed on Sep. 18, 2018 and entitled System and Method for Controlling Gas Consumption by Gas-fired Water Heaters.

FIELD OF THE INVENTION

The present invention relates to a system and a method of remotely controlling gas consumption of power vented gas-fired water heaters during an overload condition in a gas distribution bank of a gas provider containing a plurality of consumer loads.

BACKGROUND OF THE INVENTION

With the popularity of natural gas being on the rise due to high costs of electricity, consumers are resorting to a conversion of home appliances which are operated by gas energy. For example, a home can be equipped with gas stoves, gas clothes dryer, gas furnaces, gas water heaters, gas fireplaces and with many of these appliances being equipped with safety devices to automatically cut off gas supply when the burner temperature is too high or when the burner flame becomes extinct due to burner malfunction or other reasons. Like the electrical grid, with many of such appliances being used in homes connected to a gas distribution bank of a gas supplier, overload conditions created by excessive demand during daily peak demand times can occur causing a gas pressure reduction on the gas distribution bank and resulting in malfunctions of certain important gas-fired appliances such as a gas stove for cooking or gas furnace during cold weather conditions.

Many of the gas appliances have burner systems that are not entirely controllable and therefore are not capable of providing efficient combustion across an entire operating range of an appliance but only at selected air and gas flow speed, such as low, medium and high. They cannot be efficiently regulated throughout an operating range from low to high.

It is therefore desirable to control the load on a gas distribution bank of a gas provider to prevent such inconveniences to the gas consumers during peak demand times when certain gas-fired appliances are required to work efficiently, such as for example the use of a stove to permit the cooking of meals or the operation of a gas furnace during very cold weather conditions and with substantially no inconvenience to the consumer.

SUMMARY OF THE INVENTION

It is a feature of the present invention to provide a system and a method for automatically controlling gas consumption of power vented gas-fired water heaters during peak demand daily time periods to reduce the gas demand load on a gas distribution bank of a gas provider.

It is a further feature of the present invention to automatically monitor the water temperature in the water holding tank of a gas-fired power vented water heater to automatically determine if the gas supply to its burner can be reduced or shut-down for a time period to reduce the gas demand load on a gas distribution bank of a gas provider.

Another feature of the present invention is to provide a system and method for remotely controlling the operation of a power vented gas-fired water heater by a gas provider during peak demand daily periods and when necessary to do so to reduce the gas demand load on a gas distribution bank of the gas provider without inconvenience to its consumers.

According to the above features, from a broad aspect, the present invention provides a system for controlling gas consumption of a powered vented gas-fire water heater. The system comprises a water holding tank having a combustion chamber at a lower end thereof. A gas burner is located in the combustion chamber. A flue has a lower end secured for communication with the combustion chamber and a top end in communication with a power venting blower secured exteriorly of the water holding tank. An adjustable modulating gas valve is secured between the gas burner and a gas supply conduit. At least one temperature probe is secured at a predetermined location to a side wall of the water holding tank for sensing water temperature in the water holding tank at the predetermined location. A controller is provided and has a computer with a memory for storing and executing functions for the controller to control the operation of the adjustable modulating gas valve. The controller receives water temperature signals from the temperature probe for continuous monitoring of the temperature of heated water in the water holding tank at the predetermined location. The gas conduit is connected to a gas provider distribution bank network of gas consumers. A communication link is provided between the controller and the gas provider for the communication of control signals by the gas provider for causing the controller to perform command signal functions from the gas provider to reduce, resume or shut-off the gas supply to the burner by the operation of the modulating valve.

According to another broad aspect of the present invention there is provided a method of controlling gas consumption of a power vented gas fired water heater to prevent overload conditions on a gas distribution bank of a gas provider. The method comprising the following steps of:

i) communicating a control signal by the gas provider to a controller of a power vented gas-fire water heater of gas consumers connected to the gas distribution bank network of the gas provider for the controller to operate a modulating gas supply valve controlling a burner mounted in a combustion chamber of a water holding tank of the gas-fired water heater to reduce gas supply to the burner during a predetermined time period, and wherein a power venting blower is secured to a top end of a flue in communication with the combustion chamber, ii) monitoring water temperature in the water holding tank at one or more predetermined locations by the controller, the controller having a computer provided with a memory for storing and executing functions by the controller to control the modulating gas supply valve, and iii) automatically reducing the gas supply to the burner by the controller during the predetermined time period if the water temperature within the water holding tank is below a desired water temperature profile stored in a memory of the computer of the controller.

DESCRIPTION OF THE DRAWINGS

A preferred embodiment of the present invention will now be described with reference to the example of the preferred embodiment wherein:

FIG. 1 is a block diagram illustrating an example of a system for controlling gas consumption of a powered vented gas-fired water heater of a consumer connected to a gas distribution bank network of a gas provider, and

FIG. 2 is a flow chart illustrating the logic sequence of the operation of the system illustrated in FIG. 1.

DESCRIPTION OF THE PREFERRED EMBODIMENT OF THE INVENTION

Referring to FIGS. 1 and 2, there is shown generally at 10 the system of the present invention and the logic of the operation 10′ for controlling gas consumption of a powered vented gas-fired water heater 13 of a consumer connected to a gas distribution bank network 11 of a gas provider 12. As illustrated, the water heater 13 has a water holding tank 14 under which is formed a combustion chamber 15. A burner 25 is mounted in the combustion chamber 15 to heat the water 18 in the water holding tank 14. A flue pipe 16 is secured to the top wall 17 of the combustion chamber 15 and extends vertically and central through the water holding tank 14 in communication with water 18 in the tank whereby the flue is in contact with the water to heat the water in the tank. The water holding tank 14 is surrounded by insulation 19 and contained within an outer casing 20 spaced from the water holding tank wall.

A power vented blower 21 is secured to the top end 16′ of the flue pipe 16 on the top wall 20′ of the outer casing 20 for venting the products of combustion to the outside ambient air through ducting 22 within a building in which the gas-fired water heater is located. An adjustable modulating gas valve 23 is secured to a domestic gas line 24 connected to the gas supply conduit 11′ of the gas distribution bank network 11, and connected to the burner 25. At least one temperature probe 26, herein four or more probes 26, are connected to the side wall 27 of the water holding tank 14 at predetermined spaced locations for sensing the tank wall temperature which is substantially the same as the water temperature inside the water holding tank 14 adjacent to the probe. On the other hand, the probes may extend within the tank interior to directly sense water temperature. The probes 26 are connected to the controller 28 to provide to the computer 29 temperature signals for the continuous monitoring of the temperature of heated water 18 in the water holding tank 14 at the predetermined locations.

The controller 28 is provided with a computer 29 equipped with a memory 30 in which is stored functions to executed programmed functions to operate the adjustable modulating gas valve 23. The controller 28 can also operate a blower fan 31 associated with the power vented blower 21 to adjust the speed of the blower fan which in turn automatically results in an adjustment to the modulating gas valve 23 by the blower 21. As herein shown, the controller 28 is in communication with a transceiver 32 to establish a communication link, herein through the internet 33, with the remote gas provider 12 which is equipped with a computer system to communicate control signals to the controller 32 to perform command signal functions to reduce, resume or shut-off gas supply to the burner 25 by the operation of the modulating gas valve 23.

The modulating gas valve 23 is of a type known in the art and suitable for the operation of the present invention. These modulating gas valves are provided with a regulator mechanism 23′ through which gas flow is regulated. The controller 28 operates the regulator mechanism 23′ to reduce or increase the gas supply to the burner 25 to reduce or increase the heat generated by the burner 25. For example, the gas provider can call for a reduction of gas supply to all gas-fired water heaters 13 connected to its gas supply conduit 11′ by 20% or more depending on the load reduction that is deemed desirable for its gas distribution bank 11.

As mentioned above, the controller 28 can cause a reduction of the gas supply to the burner 25 by directly operating the gas regulator 23′ of the modulating gas valve 23 or by reducing the speed of the blower fan 31 of the power vented blower 21. If the modulating gas valve 23 is operated by the controller to reduce the supply of gas to the burner 25, the temperature in the combustion chamber and of the combustion gases vented through the flue pipe is reduced and this temperature reduction is sensed by the blower 21 which automatically adjusts its fan speed for the exhaust of the reduced pressure of the combustion gases. On the other hand, if the controller 28 reduces the fan speed of the blower fan 31, the blower will sense a temperature increase of the combustion gases and adjust the modulating gas valve 23 to reduce the gas supply. Accordingly, gas consumption can be reduced by either controlling the modulating gas valve 23 or controlling the blower fan 31 of the power venting blower 21.

As above mentioned, the temperature sensing probes 28 feed temperature signals to the controller computer 29 which is programmed to store in its memory 30 an actual temperature profile representative of the water temperature in the water holding tank for comparison with a desired reference water temperature profile stored in its memory to enable the computer to make a decision of an operational function to operate the gas regulator of the modulating gas valve or the blower fan or none. The reference temperature profile stored in the memory of the computer is the optimum desired water temperature profile of the gas-fired water heater. The memory may also have stored therein a reduced water temperature profile indicative of reduced water temperature suitable for use by the consumer during reception of a command signal from the provider to reduce consumption. If the water temperature in the tank is within the reduced profile, then the controller will shut-off the gas supply to the burner until the temperature of the water falls below the reduced profile and then the controller will operate the modulating valve to maintain the reduced gas supply mode until it receives a command signal from the gas provider 12 to resume normal operation.

It is pointed out that the communication link between the controller 28 and the gas provider 12 is herein illustrated as a wireless communication link but could also be provided through a variety of different communication means, such as a telephone communication link. Therefore, the present invention is not limited to the illustrated wireless communication. Also, the communication through the internet can be done through various types on wireless communication software and using remote control devices, such as a smart phone, a tablet, desktop computer 34 as illustrated, a laptop computer or a cell phone 34′ also herein illustrated or other suitable communication devices that can communicate through the internet by the use of wireless technologies.

Although not shown, the system 10 may incorporates a subscriber module conveniently mounted to provide a visual display to display operational conditions of the system including the status of any command signal currently in operation by the system. The module would be provided with inputting means, such as a touch switch, to permit the subscriber to override the command signal function of the provider and thereby preventing the reduction of its gas supply to the gas-fired burner of the water heater should the consumer not want a reduction in the water temperature of its water heater during a gas supply overload condition which usually occurs during daily peak consumption time periods.

The method of operation of the present invention will now be briefly described having above described to construction and interrelationship of the component parts of the system. In summary, the method comprises communicating a control signal by a gas provider 12 to a controller 28 of a power vented gas-fire water heater 13 of gas consumers of a gas distribution bank network 11 of the gas provider to cause the controller 28 to operate a modulating gas supply valve 23 controlling a burner 25 mounted in a combustion chamber 15 of a water holding tank 14 of the gas-fired water heater to reduce gas supply to the burner during a predetermined time period. Temperature sensors 26 monitor water temperature in said water holding tank 14 at one or more predetermined locations of the tank. The controller 28 is provided with a computer 29 provided with a memory 30 for storing and executing functions by the controller to control the modulating gas supply valve. The gas supply to the burner is controlled during the predetermined time period if the water temperature within the water holding tank is below a water temperature profile stored in the memory of the computer of the controller.

As mentioned above, the controller 28 can operate the gas regulator mechanism 23′ of the modulating gas supply valve 23 to reduce gas supply to the burner and thereby reduce the temperature of exhaust combustion gas in the flue causing the power venting blower to reduce the speed of a fan associated therewith in a proportional amount to the reduction of the temperature of the combustion gases. On the other hand, the controller 28 can operate the blower fan 31 of the power vented blower 21 to reduce the speed of the fan which in turn causes the blower to adjust the modulating gas valve 23 to reduce gas supply to the burner. Also, these control command signals are usually transmitted during daily peak consumption time periods when there is the likely hood of an excess demand for gas by the consumers branched to the gas line of a distribution bank of the gas supplier or during emergency conditions.

The purpose of the temperature probes 26 is to monitor water temperature in the water holding tank at a plurality of spaced-apart locations adjacent the side wall 27 of the water holding tank 14 to detect the temperature of the side wall at the spaced-apart locations to generate a plurality of the temperature signals to the computer for storage in its memory to develop an actual temperature profile of water temperature in the tank. The temperature values detected on the side wall of the tank are representative of actual temperature of water inside the water holding tank at the spaced-apart locations. See U.S. patent application Ser. No. 14/544,994 relating to Conduit for the Removable Positioning of Temperature Sensors in a Water Heater and Method, and for which a patent is granted.

The method also comprises initially storing in the memory 30 of the computer 29 a reference water temperature profile representative of a desirable hot water profile of the water heater for comparison with the actual temperature profile whereby to enable the computer to take decisions regarding the control of the operation of the gas regulator mechanism or not. The controller 28 also communicates to the provider 12 through the transceiver 32 the status of its power vented gas-fired water heater to permit the gas provider to make an informed decision if gas supplied to other gas consuming appliances of the consumer connected to the gas distribution bank 11 should be shut down.

It is within the ambit of the present invention to encompass all obvious modifications of the example of the preferred embodiment described herein provided such modifications fall within the scope of the appended claims. 

1. A method of controlling gas consumption of a power vented gas fired water heater to prevent overload conditions on a gas distribution bank network of a gas provider, said method comprising the steps of: i) communicating a control signal by said gas provider to a controller of a power vented gas-fire water heater of gas consumers of said gas distribution bank network of said gas provider for said controller to operate a modulating gas supply valve controlling a burner mounted in a combustion chamber of a water holding tank of said gas-fired water heater to reduce gas supply to said burner during a predetermined time period, and wherein a power venting blower is secured to a top end of a flue in communication with said combustion chamber, ii) monitoring water temperature in said water holding tank at one or more predetermined locations by said controller, said controller having a computer provided with a memory for storing and executing functions by said controller to control said modulating gas supply valve, and iii) automatically reducing the gas supply to said burner by said controller during said predetermined time period if said water temperature within said water holding tank is below a desired water temperature profile stored in a memory of said computer of said controller.
 2. The method as claimed in claim 1 wherein said step (i) comprises said controller operating a gas regulator mechanism of said modulating gas supply valve to reduce gas supply to said burner and thereby reduce the temperature of exhaust combustion gas in the flue causing said power venting blower to reduce the speed of a fan associated therewith in a proportional amount to the reduction of said exhaust combustion gas temperature.
 3. The method as claimed in claim 1 wherein said step (i) comprises said controller operating a power vented blower fan of said power vented blower to reduce the speed of said fan, said power vented blower controlling a gas regulator mechanism of said modulating gas supply valve to reduce the supply of gas to said burner in a proportional amount to the reduced fan speed.
 4. The method as claimed in claim 1 wherein in step (i) said control signal is transmitted during daily peak consumption time periods if there is an excess demand for gas by said consumers of said distribution bank.
 5. The method as claimed in claim 1 wherein said step (ii) comprises monitoring water temperature in said water holding tank at a plurality of spaced-apart locations adjacent a side wall of said water holding tank to detect the temperature of said side wall at said spaced-apart locations to generate a plurality of said temperature signals to said computer for storage in said memory to develop an actual temperature profile of water temperature in said tank at said predetermined locations, said temperature signals of said side wall being representative of actual temperature of water inside said water holding tank at said spaced-apart locations.
 6. The method as claimed in claim 5 wherein there is further provided initially storing in said memory a reference water temperature profile representative of a desirable hot water profile as well as a reduced temperature profile for comparison with said actual temperature profile whereby to enable said controller to execute the operation of said gas regulator mechanism or not.
 7. The method as claimed in claim 16 wherein there is further provided the step of said controller of said gas consumer communicating the status of its power vented gas-fired water heater to said gas provider to permit said gas provider to make an inform decision if gas supplied to other gas consuming appliances of said consumer connected to said gas distribution bank should be reduced or shut down.
 8. The method as claimed in claim 1 wherein said step (i) of communicating is a wireless communication link through the internet using a remote control device, such as a smart phone, tablet, desktop computer, laptop, telephone, cell phone or other suitable communication devices that can communicate through the internet by the use of wireless technologies. 